Jasic EVO 2.0 EM-160C Operator's Manual
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Jasic EVO 2.0 EM-160C Operator's Manual

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Summary of Contents for Jasic EVO 2.0 EM-160C

  • Page 2: Your New Product

    Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and trouble free operation. Please call your Jasic distributor in the unlikely event of a problem occurring. Please record below the details from your product as these will be required for warranty purposes and to ensure you get the correct information should you require assistance or spare parts.

  • Page 3: Table Of Contents

    Guide to Lift TIG TIG Torch Description and Spare Parts List TIG Welding Troubleshooting Maintenance Troubleshooting Troubleshooting Error Codes WEEE Disposal RoHS Compliance Declaration UKCA Declaration of Conformity EC Declaration of Conformity Statement of Warranty Schematic Options and Accessories Notes Jasic Contact Details...

  • Page 4: Safety Instruction

    SAFETY INSTRUCTIONS These general safety norms cover both arc welding machines and plasma cutting machines unless otherwise noted. The user is responsible for installing and operating the equipment in accordance with the enclosed instructions. It is important that users of this equipment protect themselves and others from harm, or even death. The equipment must only be used for the purpose it was designed for.

  • Page 5: Ppe

    SAFETY INSTRUCTION Use of Personal Protective Equipment (PPE) Welding arc rays from all welding and cutting processes can produce intense, visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. • Wear an approved welding helmet fitted with an appropriate shade of filter lens to protect your face and eyes when welding, cutting or watching.

  • Page 6: Fume And Welding Gases

    SAFETY INSTRUCTION Safety against fumes and welding gases The HSE have identified welders as being an ‘at risk’ group for occupational diseases arising from exposure to dusts, gases, vapours and welding fumes. The main identified health effects are pneumonia, asthma, chronic obstructive pulmonary disease (COPD), lung and kidney cancer, metal fume fever (MFF) and lung function changes.

  • Page 7: The Working Environment

    SAFETY INSTRUCTION The working environment Ensure the machine is mounted in a safe and stable position allowing for cooling air circulation. Do not operate equipment in an environment outside the laid down operating parameters. The welding power source is not suitable for use in rain or snow. Always store the machine in a clean, dry space.

  • Page 8: Rf Declaration

    SAFETY INSTRUCTIONS Fire awareness The cutting and welding process can cause serious risks of fire or explosion. Cutting or welding sealed containers, tanks, drums or pipes can cause explosions. Sparks from the welding or cutting process can cause fires and burns. Check and risk assess the area is safe before doing any cutting or welding.

  • Page 9: Materials And Their Disposal

    For more detailed information please refer to the HSE website www.hse.gov.uk PACKAGE CONTENTS AND UNPACKING Supplied within your new Jasic EVO product package will be the following items with each model. Use care when unpacking the contents and ensure all items are present and not damaged.

  • Page 10: Description Of Symbols

    DESCRIPTION OF SYMBOLS Read this operation manual carefully before use. Warning in operation. Single-phase static frequency converter-transformer rectifier. Symbol of single-phase AC power supply and rated frequency. Can be used in the environment which has high risk of electric shock. Degree of protection, such as IP23S.
  • Page 11 DESCRIPTION OF SYMBOLS Read this operation manual carefully before use. Mixed gas welding (80% argon + 20% CO2) of carbon steel Mixed gas welding (80% argon + 20% CO2) of flux-cored carbon steel Self-shielded welding of carbon steel 100% argon shielding of aluminum magnesium alloy Mixed gas welding (98% argon + 2% CO2) of stainless steel Welding type selection: welding base metal and gas Welding wire diameter...

  • Page 12: Product Overview

    PRODUCT OVERVIEW These digital EM-160C and EM-200C MIG inverter welding machines feature advanced technology that provides excellent welding performance along with user experience. They provide a stable arc that is ideal for MIG, DC Lift TIG and MMA which can weld carbon steel, low alloy steel, stainless steel and other materials.

  • Page 13: Technical Specifications

    TECHNICAL SPECIFICATIONS Parameter Unit Jasic MIG EM-160C PFC Jasic MIG EM-200C PFC Rated input (U1) AC 95 ~ 265V AC 95 ~ 265V Rated input Frequency 50/60 50/60 Input Voltage 115V 230V 115V 230V MMA 13.8 MMA 10.1 MMA 14.3 MMA 12.5...

  • Page 14: Description Of Controls

    DESCRIPTION OF CONTROLS - JASIC MIG EM-160 and EM-200 Front view Jasic MIG EM-160C and EM-200C 1. Digital user control panel (see lower down for further information) 2. Wireless remote control (optional) 3. "+" Output terminal*, The connection for the torch in MIG mode 4.
  • Page 15 DESCRIPTION OF CONTROLS - JASIC MIG EM-160C and EM-200C Side view Jasic MIG EM-160 and EM-200 1. Gas Solenoid Valve: When activated this valve allows the gas to flow through the machine euro outlet adaptor and the welding torch 2. Wire spool holder and tensioner: Allows a 5Kg (200mm dia) reel of wire to be located in place via an alignment pin and then locked in place with the locking nut.

  • Page 16: Installation

    Lifting The Jasic EM-160C or EM-200C do have an integrated handle for easy hand lifting only. Always ensure the machine is lifted and transported safely and securely. Location The machine should be located in a suitable position and environment.
  • Page 17 Gas Connections The gas regulator is designed to reduce and control the high pressure gas from a cylinder or pipeline to the working pressure required for the Jasic TIG machine. Before fitting the regulator, clean the cylinder valve outlet. Match the regulator to cylinder and before connecting, ensure the regulator and the regulator inlet and cylinder outlet match.
  • Page 18 INSTALLATION OF WIRED REMOTE CONTROL (STANDARD) Wired hand-held remote-control connection As standard the EVO MIG EM-160 and EM-200 machines are fitted with a 9 pin remote control socket (1). This allows for the matching 9 pin plug (2) of the hand held remote control or a foot pedal to be connected directly to the machine to offer the user remote operation control.

  • Page 19: Control Panel Description

    CONTROL PANEL - JASIC MIG EM-160C and EM-200C 1. Remote control selection: Pressing this button will set current control from the panel to a remote device such as a foot pedal, TIG torch remote potentiometer or a remote control device for MMA.
  • Page 20 CONTROL PANEL - FUNCTIONS Digital Display The top digital meter as shown below, is used to display many machine details including: current, wire feeding speed, plate thickness parameters and error codes etc. Below is listed some of the data that will be noted via this display. •...
  • Page 21 CONTROL PANEL - FUNCTIONS Digital Display The bottom digital meter as shown below, is used to display the voltage, inductance/arc force and burn back time. • When not welding, the preset value of voltage is displayed. If no operation is performed for a long time, the default parameters are displayed.
  • Page 22 CONTROL PANEL - FUNCTIONS Welding mode selection area and switch The welding mode selection zone (shown right) contains the welding mode selection switch and corresponding indicators MIG, MMA and Lift TIG. Pressing the green mode selection key will allow you to choose the required welding mode and the corresponding indicator will be lit according to your selection.
  • Page 23 CONTROL PANEL - FUNCTIONS Warning indicators Over temperature The overheat indicator light indicates that the machine has entered overheat protection and has stopped welding output, the machine will re-activate once the unit has cooled down. Do not turn off the machine when this indictor illuminates, wait for a while, and then continue welding after the overheat indicator has turned off.
  • Page 24 CONTROL PANEL - FUNCTIONS VRD indicator The VRD LED will be lit when the machine is in MMA mode and the VRD function is enabled. When the VRD indicator is lit the output voltage is 11.5V. Please Note: • The VRD LED will go off when the welding arc is established. •...
  • Page 25 CONTROL PANEL - SETTINGS Configuration Settings Welding Engineers Mode functions The Welding Engineer Mode function allows users to adjust and set background default parameters or functions as follows: Press and hold the top parameter adjustment knob for 5s in startup state. After pressing and holding the top parameter adjustment knob"...
  • Page 26 CONTROL PANEL - SETTINGS Configuration Settings Welding Engineers Mode functions (continued) Background Parameter Default Function definition function value Setting Port-flow time for either MIG or Lift TIG will depend on which welding mode you are in when entering Welding Engineer Mode. MIG: 0.5 Post-flow time If the "Welding Mode"...
  • Page 27 CONTROL PANEL - FUNCTIONS Configuration Settings (Engineers mode) Restore Factory Settings To reset to factory settings for the EM-160C or the EM-200C, press and hold the welding mode button for 5 seconds to restore all factory settings. After holding the button for 1 second the display window will show the start of a count down from 3 to zero.

  • Page 28: Remote Control (Wired And Wireless)

    CONTROL PANEL - FUNCTIONS Wired (Foot pedal / hand-held) Remote Control A 9 pin remote control socket is fitted as standard to the front panel of the machine, see page 79 for optional remote controls) 1) Before welding, press the remote-control function button to enable the remote control function.

  • Page 29: Remote Control Socket

    REMOTE CONTROL SOCKET The Jasic MIG EM-160C and EM-200C are fitted with 9 pin remote control socket located on the front panel which is used to connect various remote control devices, for example: a TIG torch with trigger switch, a TIG torch with mounted switch and current adjustment dial, a foot pedal or other similar devices including MMA remote control devices.

  • Page 30: Operating Mig

    OPERATION MIG MIG/MAG welding Insert the welding torch (C) into the “Euro connector for torch in MIG” output socket on the front panel of the machine and tighten it. Insert the trailing cable plug (A) into the “+” output terminal of the welding machine and tighten it clockwise.
  • Page 31 OPERATION - MIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG/MAG Standard Welding Mode MIG - Metal Inert Gas Welding, MAG - Metal Active Gas Welding, GMAW - Gas Metal Arc Welding MIG welding was developed to help meet production demands of the war and post war economy which is an arc welding process in which a continuous solid wire electrode is fed through a MIG welding...
  • Page 32 OPERATION - MIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG/MAG standard welding mode Selecting MIG Welding mode: Press the MIG/MMA/Lift TIG button (C) to select MIG welding mode. Upon selecting MIG, only the MIG mode corresponding icon will be lit up as shown right.
  • Page 33 For alternative trigger modes details, please see page 37. Standard MIG Torch or Spool Gun Mode: The Jasic EM-160C and EM-200C machines can be used with the optional spool gun part number JE-SP250-6 which is a Euro style spool gun which will connect to the machine via the Euro outlet connector.
  • Page 34 OPERATION - MIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG/MAG standard welding mode When in standard MIG mode, you can now adjust various MIG parameters such as pre & post gas flow, burnback voltage and initial slow wire feed speed and these which are adjusted via the welding engineer mode (WEM) function that allows the users to adjust a number of background default parameters or functions.
  • Page 35 OPERATION - MIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG/MAG Synergic Welding Mode Synergic Welding Mode: Synergic mode is where Welding Power (Voltage) and Wire Feed Speed are adjusted together, rather than separately, via a single Control.
  • Page 36 OPERATION - MIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG/MAG Synergic Welding Mode Synergic Welding Control: The top control dial and display area (P) when synergic mode is selected amperage control becomes the default adjustment setting on this display (as shown left).
  • Page 37 OPERATION - MIG Torch trigger operation modes 2T operation mode Press the torch trigger to initiate the welding arc, the arc is extinguished when you release the trigger. 焊枪开关 提前送气 Torch trigger Pre-flow 空载电压 No load voltage 防粘时间 送 气 Burnback Gas supply 滞后送气时间...

  • Page 38: Guide To Mig/Mag Welding

    GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG process description The MIG process was first patented for the welding of aluminium in 1949 in the USA. The process uses the heat that is generated by an electric arc formed between a bare consumable wire electrode and the work piece.
  • Page 39 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Notes for the welding beginner This section is designed to give the beginner who has not yet done any welding some information to get them going.
  • Page 40 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG controls The main basic controls for the MIG/MAG system are wire feed speed and voltage. Wire feed speed The wire speed is directly related to the current.
  • Page 41 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Modes of Transfer Dip or short circuit mode In the dip or short circuit, the wire (electrode) touches the work piece and a short circuit is created.
  • Page 42 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Modes of Transfer Spray Arc Mode The Spray arc mode is used with high voltage and current. Metal is projected in the form of a fine spray of molten droplets of the electrode, propelled across the arc to the work piece by an electromagnetic force without the wire touching the weld pool.
  • Page 43 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Welding Mode - Standard Current or wire feed speed, workpiece thickness adjustment has no relation with voltage adjustment and other parameters.
  • Page 44 GUIDE TO MIG/MAG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Burn Back In the event that the welder was to stop welding and all functions of the machine stopped simultaneously then the consumable filler wire would in all likelihood freeze in the weld pool.

  • Page 45: Spool Gun Operation

    Spool gun part number is JE-SP250-6 Spool Gun Welding Mode The Jasic EVO EM-160 & EM-200C machines can both be used with our optional spool gun which is a Euro style spool gun that connects to the EVO MIG machines via the Euro outlet connector.

  • Page 46: Mig Welding Chart

    MIG WELDING GUIDE...

  • Page 47: Mig Welding Problems

    MIG WELDING PROBLEMS Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG welding defects and prevention methods Defect Possible cause Action Poor material Check the material is clean...
  • Page 48 MIG WELDING PROBLEMS Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MIG welding defects and prevention methods Defect Possible cause Action Heat input too high Use lower amperage or smaller electrode...

  • Page 49: Mig Torch Description And Spare Parts List

    Please Note: Package contents may very depending on country location and package part number purchased PLEASE NOTE: Check torch supplied with your package to ensure it matches the above details. The product maybe supplied with a Jasic orange torch handle...
  • Page 50 Please Note: Package contents may very depending on country location and package part number purchased PLEASE NOTE: Check torch supplied with your package to ensure it matches the above details. The product maybe supplied with a Jasic orange torch handle.

  • Page 51: Mma Setup

    MMA SETUP Output connections Electrode polarity is generally determined by the type of welding rod being used although in general when using manual arc welding electrodes the electrode holder is connected to the positive terminal and the work return to the negative terminal. Generally, there are two connection methods of DC welder: DCEN and DCEP connection.

  • Page 52: Operating Mma

    OPERATION - MMA Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MMA welding MMA (Manual Metal Arc), SMAW (Shielded Metal Arc Welding) or just Stick Welding.
  • Page 53 OPERATION - MMA Before starting any welding activity ensure that you have suitable eye protection and protective clothing as, welding rays, spatter, smoke and high temperatures produced in the process may cause injury to personnel. Also take the necessary steps to protect any persons within the welding area that may cause injury too. MMA welding Select MMA welding mode by pressing the green arrow butting until the MMA symbol is illuminate as shown in the image right...
  • Page 54 OPERATION - MMA Before starting any welding activity ensure that you have suitable eye protection and protective clothing as, welding rays, spatter, smoke and high temperatures produced in the process may cause injury to personnel. Also take the necessary steps to protect any persons within the welding area that may cause injury. MMA welding Arc force: Arc force prevents the electrode sticking when welding.

  • Page 55: Guide To Mma Welding

    GUIDE TO MMA WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MMA process tips and guides Typical welder set up 1.
  • Page 56 GUIDE TO MMA WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. MMA arc striking Tap Technique - Lift the electrode upright and bring it down to strike the work piece. After forming a short circuit, quickly lift up about 2 ~ 4mm and arc will be ignited.
  • Page 57 GUIDE TO MMA WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Fillet welding The electrode should be positioned to split the angle i.e. 45º. Again the electrode should be inclined in the direction of travel at around 10º...
  • Page 58 GUIDE TO MMA WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Notes for the welding beginner This section is designed to give the beginner who has not yet done any welding some information to get them going.

  • Page 59: Mma Welding Troubleshooting

    MMA WELDING TROUBLESHOOTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Arc welding defects and prevention methods Defect Possible cause Action Amperage too high for the Reduce amperage or utilise larger...

  • Page 60: Lift Tig Setup

    LIFT TIG SETUP Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. LIFT TIG welding mode Terms used: TIG – Tungsten Inert Gas, GTAW – Gas Tungsten Arc Welding. TIG welding is an arc welding process that uses a non-consumable tungsten electrode to produce the heat for welding.

  • Page 61: Operating Lift Tig

    OPERATION - LIFT TIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Lift TIG operation steps The selection area for selecting the Lift TIG mode, pressing the green welding process mode selection button until the (bottom) Lift TIG DC LED is illuminated as shown left for either the EM-160C or the EM-200C model.
  • Page 62 OPERATION LIFT TIG Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Indicator for 2T Torch Trigger Operation Indicator for 4T 2T mode (normal trigger control) The 2T ( LED light will illuminate when the power source is in 2T welding mode.

  • Page 63: Guide To Lift Tig

    GUIDE TO TIG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. TIG torch body and components The torch body holds the various welding consumables in place as shown and is covered by a either a rigid phenolic or rubberised covering.
  • Page 64 GUIDE TO TIG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. TIG welding electrodes TIG welding electrodes are a ‘non consumable’ as it is not melted into the weld pool and great care should be taken not to let the electrode contact the welding pool to avoid weld contamination.
  • Page 65 The TIG process can use both non contact and contact methods to provide arc starting. Depending on the Jasic model, the options are indicated on a selector switch on the front control panel of the power source. The most common method of arc starting is ‘HF’ start. This term is often used for a variety of starting methods and covers many different types of start.
  • Page 66 The Jasic EVO EM range offers Lift TIG mode utilising the TIG torch switch operation mode which starts the process with the internal gas valve opening to start the gas flow first.
  • Page 67 GUIDE TO DC TIG WELDING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Manual DC TIG Welding Amperage Guide- Mild Steel and Stainless Steel Base Metal Base Metal Tungsten...

  • Page 68: Tig Torch Description And Spare Parts List

    - - JSP-01 2 Pin Control Plug (TIG Torch) Check torch supplied with your package to ensure it matches the above - - 10004655 5 Pin Control Plug (Remote) details. The product maybe supplied with a Jasic orange torch handle...

  • Page 69: Tig Welding Troubleshooting

    TIG WELDING TROUBLESHOOTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. TIG welding defects and prevention methods Defect Possible cause Action Set up for DCEP Change to DCEN...
  • Page 70 TIG WELDING TROUBLESHOOTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. TIG welding defects and prevention methods Defect Possible cause Action Excessive bead build up, poor Increase the welding amperage...
  • Page 71 TIG TORCH TROUBLESHOOTING TIG welding defects and prevention methods The TIG torch used for lift TIG welding comprises of several items which ensure current flow and arc shielding from the atmosphere. Regular maintenance of the welding torch is one of the most important measures to ensure its normal operation and extend lifespan.

  • Page 72: Maintenance

    MAINTENANCE The following operation requires sufficient professional knowledge on electric aspects and comprehensive safety knowledge. Make sure the input cable of the machine is disconnected from the electricity supply and wait for 5 minutes before removing the machine covers. In order to guarantee that the arc welding machine works efficiently and in safety, it must be maintained regularly.

  • Page 73: Troubleshooting Error Codes

    The below is a list of error codes for the Jasic EVO EM-160 and EM-200 welding machines. Error...

  • Page 74: Weee Disposal

    Jasic has a relevant recycling system which is compliant and registered in the UK with the environment agency. Our registration reference is WEEMM3813AA.

  • Page 75: Ukca Declaration Of Conformity

    UKCA Declaration of Conformity...

  • Page 76: Ec Declaration Of Conformity

    EC DECLARATION OF CONFORMITY...

  • Page 77: Statement Of Warranty

    3 month warranty. Jasic shall in no event be responsible for any third party expenses or expenses/costs or any indirect or consequential expenses/costs.

  • Page 78: Schematic

    SCHEMATIC...

  • Page 79: Options And Accessories

    Cable Plug 35-50mm JE-SP250-6 Spool Gun SP250 6m WP26-12JE WP26 Euro Style TIG Torch 4m JH-HDX Jasic HD True Colour Auto Darkening Welding Helmet HRC-01 Wired hand held remote current control HRC-02 Wireless hand held remote current control FRC-01 Wired foot pedal remote current control...
  • Page 80 OPTIONAL REMOTE CONTROL DEVICES Control Wireless Welding Name Model Image Type Receiver Mode Wired foot pedal FRC-01 remote control Wired Wired handheld HRC-01 TIG/MMA remote control Wireless handheld HRC-02 TIG/MMA remote control Wireless Foot pedal FRC-02 Wireless remote control Wireless TIG/MMA Transceiver NOTES...

  • Page 81: Notes

    NOTES _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________...

This manual is also suitable for:

Evo 2.0 em-200c

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